880001 d

DOCUMENT NAME: 880001 REV A

System Description

HCI(S) Top Drive System

500/650T HCI(S) 750/1205HP

smithp

SYSTEM DESCRIPTION COPYRIGHT AND DISCLAIMER

880001 REV A 500/650T HCI(S) 750/1205HP TESCO CORPORATION, 2004III

Tesco Corporation ("Tesco") has made every effort to ensure that this document contains accurate and current information for the Tesco top drive, however, the document is intended to be used in conjunction with a complete training program and on-site supervision and Tesco does not warrant or guarantee that the information contained herein is either complete or accurate in every respect, and the reader hereby protects, indemnifies and holds harmless Tesco Corporation together with its directors, officers, employees and agents from and against all liability for personal injury, death or property damage to any person arising directly or indirectly from the use by the reader of the information contained in the document.

Tesco Corporation 2004

Contact InformationCorporate Head Office

6204 - 6A St. S.E.Calgary, AB T2H 2B7

Canadawww.tescocorp.com

Telephone: (403) 233-0757Fax: (403) 252-3362

REVISION INFORMATION SYSTEM DESCRIPTION

TESCO CORPORATION, 2004 500/650T HCI(S) 750/1205HP 880001 REV AIV

Revision Information

Version Date Description of Changes

Rev A April 2004 General revisions and conversion to FrameMaker

SYSTEM DESCRIPTION TABLE OF CONTENTS

880001 REV A 500/650T HCI(S) 750/1205HP TESCO CORPORATION, 2004V

TABLE OF CONTENTS

Chapter 1: About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Chapter 2: Top Drive System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Introduction and General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Shipping Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Container 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Container 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Container 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Top Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Load Collar and Load Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Pipe Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Top Drive Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Handling Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Pump Drive and Filter Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Hydraulic Oil Reservoir/Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Extend Frame and Extend Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Torque Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Torque Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Torque Beam and T-bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Power (Closed-Loop) Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Case Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Drillers Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Integrated Rotary Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Elevators and Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Additional Safety Valve and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Subs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Grabber Drill Pipe Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Rotary Table Stabilizer Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TABLE OF CONTENTS SYSTEM DESCRIPTION

TESCO CORPORATION, 2004 500/650T HCI(S) 750/1205HP 880001 REV AVI

Rotary Hose and Standpipe Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Other Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

SYSTEM DESCRIPTION

880001 REV A 500/650T HCI(S) 750/1205HP TESCO CORPORATION, 20041

CHAPTER 1: ABOUT THIS DOCUMENT

This document contains a description of the major components of the Hydraulic Compact Inte-grated (HCI(S)) Top Drive System with integrated quill and optional integrated swivel.

A complete HCI(S) Top Drive System consists of the following:

top drive power unit interconnecting service loop and reel torque arrest system associated buildings, containers and equipment

This document provides a brief description of each major component, as well as a list of avail-able spares and options.

Table 1-1: Where to Find More Information

For information on Refer to

installation rig up commissioning pre-operational checklists rig out procedures

Installation Guide

setting torque and speed driller's panel functions and operating descriptions making connections drilling ahead tripping freeing stuck pipe

Operations Guide

load path inspections maintenance/service schedules component disassembly and reassembly

Maintenance Guide

Tesco manufactured parts and part numbers Parts List

troubleshooting Troubleshooting Guide (where available)

electrical schematics hydraulic schematics cooling schematics gearbox lubrication schematics

System schematics

available options and spares Tesco Representative

ABOUT THIS DOCUMENT SYSTEM DESCRIPTION

TESCO CORPORATION, 2004 500/650T HCI(S) 750/1205HP 880001 REV A2

smithp

SYSTEM DESCRIPTION


CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION

INTRODUCTION AND GENERAL SPECIFICATIONS

The HCI(S) top drive is designed for use on land and offshore rigs that require high torque and rpm in a compact unit. The HCI(S) top drive is powered using an independent hydraulic power unit.

To create the optimum power supply system required for each of its top drives, Tesco com-bines industry proven prime movers with its own series of hydraulic pump drives and filtration equipment.

The HCI(S) top drive is powered using one of the following power unit configurations:

1205 hp prime mover with a six-pump drive 750 hp prime mover with a four-pump drive

Metric unit conversions (in brackets) have been provided for convenience only. All prod-uct specifications use the original imperial units unless indicated otherwise.

All weight values are approximate.

Table 2-1: HCI(S) Top Drive Specifications

Specification Details

Top Drive 500/650T HCI(S) 750/1205HP

Rated Capacity 500 ton(454.5 metric ton)

650 ton(590.9 metric ton)

Weight of the top drive plus: elevators elevator links counter balance swivel (if applicable)

11,800 lb. (5352.39 kg)17,800 lb. (8073.94 kg) with optional swivel

12,300 lb. (5579.17 kg18,300 lb. (8300.74 kg) with optional swivel)

Length 14 ft. 4 in. (4.36 m)20 ft. (6.1 m) with optional swivel

Width 47.25 in. (1.2 m)

Horsepower Dependent on the prime mover and pump configuration:1205 hp (898.57 kW)6 pump drive750 hp (559.27 kW)4 pump drive

TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION


SHIPPING CONTAINERS

HCI(S) top drive systems are typically shipped in ocean shipping containers. Each container is 20 ft. (length) x 8 ft. (width) x 8 ft. 6 in. (height) (6.1 m x 2.4 m x 2.6 m).

Container 1

Approximate weight: 31,000 lb. (14061.36 kg)

Contents:

top drive 37 C multi-conductor cable and storage reels links transformer (optional) spare parts

Note: Some countries require that spare parts be shipped separately from the original equipment. In these cases, spare parts will be crated and shipped in a separate container.

Container 2


Contents:

power unit and pump drive torque arrest system components

Container 3


Contents:

two rig up baskets hose reel skid hydraulic oil reservoir and cooling skid service loop components, including the cable reel

Table 2-2: Torque Arrest System Specifications

Specification Details

Weight of the following: torque track anchor beam torque bushing clamps

17,600 lb. (7983.23 kg)

Track Length 145 ft. (44.2 m) standard

SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION


TOP DRIVE COMPONENTSFigure 2-1: HCI(S) Top Drive General Assembly

1. Optional Swivel2. Quill3. Gearbox4. Mainframe Assembly5. Load Collar6. Pipe Handler Assembly7. Load Nut8. Link Tilt Cylinders9. Mudsaver Valve10.Saver Sub11.Grabber Assembly12.Elevator Links13.Elevator



Main Frame

The main frame houses the gear train and the associated hydraulic control equipment for the robotic functions of the top drive.

Gearbox The gearbox couples two hydraulic motors to the gear train. The motors are bi-directional hydraulic vane type, and the have pressures ratings of

5,000 psi (34.5 MPa) continuous. The gearbox houses gear reduction and forced lubrication systems. The integral drive hub is internally splined to accept the integrated drive quill and the

optional integrated swivel. The quill can be removed easily without dismantling the gearbox.

Load Collar and Load Nut

The load collar and load nut transfer loads from the elevator links to the quill.

Mudsaver Valve

The mudsaver valve is a double-ball crank valve that acts as a mudsaver and lower Kelly cock. The mudsaver remote actuator can be operated from the drillers panel.

Pipe Handler

The pipe handler mechanism has the following features:

Continuous rotation: The pipe handler is capable of 360 bi-directional rotation. It can be locked into position every 2.6.

Elevator Link Tilt Cylinders: These allow extension and retraction of the elevators 35 forward from the vertical position and 55 backward from the vertical position.

Grabber (back-up wrench): The grabber acts as a back-up tong for making or breaking connections at any point in the mast. The grabber will accommodate tool joints from 3-1/8 in. to 8-3/4 in. OD. The grabber features an automatic thread feed compensation for make up and break out operations, and uses standard tong dies.

Top Drive Power Supplies

The top drive motor is powered by axial pumps, which are located on the power unit. All top drive robotic functions are powered by an auxiliary hydraulic system, which is located on the prime mover module.

Handling Frame

The top drive is shipped in its own handling frame. This frame allows you to transport and handle the top drive by using standard rig moving equipment.



POWER UNIT

The HCI(S) power unit consists of the following:

prime mover module pump drive and filter manifold module hydraulic oil reservoir, cooling system and hose storage reel

Prime Mover

The prime mover is a skid-mounted diesel engine (750 hp Caterpillar 3412 or 1205 hp DDEC 16V92). Prime movers are equipped with a fuel day tank, an air starter, standard instrumenta-tion packages, and appropriate safety and emergency shutoffs.

Pump Drive and Filter Manifold

The pump drive/filter manifold is skid-mounted and includes the following equipment:

variable displacement, bi-directional axial piston pumps (four or six) charge pump flow meters and temperature gauges a series of hydraulic oil filters hot oil shuttle (to assist with oil cooling) auxiliary hydraulic pump and motor

The auxiliary hydraulic equipment includes the following:

a gear pump (2,000 psi, 7gpm; 13.79 MPa, 26.5 liters/minute) 10 hp (7.46 kW) explosion-proof electric motor associated filters and controls

Hydraulic Oil Reservoir/Cooler

The hydraulic oil reservoir/cooler is skid-mounted and contains the hydraulic oil storage reser-voir and cooling system components. All reservoirs are equipped with a level gauge, tempera-tures gauges, and return oil filters.

Cooling System Components

The cooling system components provide cooling for hydraulic oil used by the power and aux-iliary hydraulics systems. The main components are:

air cooler: this is a Modine heat exchanger, controlled by a thermostat, that cools the hydraulic oil before it is returned to the tank

(optional) water cooler: this is a frame and plate heat exchanger that provides additional cooling; refer to Other Available Options on page 13

reservoir circulating pump: this pump provides cooling for the oil reservoir; this pump can also be used as a replacement for the auxiliary hydraulic pump, if required



Figure 2-2: HCI(S) Prime Mover, Pumps and Filter Manifold

Prime Mover

Pump Drive

Filter Manifold

Figure 2-3: HCI(S) Oil Reservoir, Cooling System and Hose Reel

Electrical Panel(480V)

Oil Reservoir

Air Cooler Hose Reel



TORQUE ARREST SYSTEM

The torque arrest system is typically shipped in the second standard sea container. It consists of the following components:

extend frame torque bushing extend arms extend hydraulic cylinders torque track T-bar torque beam, torque beam clamps, stabilization devices, and all required rig up items

Extend Frame and Extend Arms

The extend frame is pinned to the top drive. It allows you to extend the top drive away from the torque track.

Torque Bushing

The torque bushing is attached to the extend frame. Ultra High Molecular Weight (UHMW) inserts reduce friction as the top drive moves along the torque track. No lubrication is required.

Torque Track

The torque track, in conjunction with the torque beam and T-bar, transfers reactive torque to the lower section of the derrick and the substructure. The track is suspended from the crown by a cable hanging assembly, and is mounted with a simple clamp anchoring arrangement. Track components can be configured to fit most mast heights.

Torque Beam and T-bar

The torque beam is mounted on the rig, typically to the lowest strongback. It is then connected to the torque track via a T-bar.



Figure 2-4: Torque Arrest System

1. Torque Bushing2. Extend Frame3. Extend Cylinders4. Extend Arms5. Torque Track



SERVICE LOOP

Service loop components, including the drillers panel and hose reel, are typically shipped in the second standard sea container. The hoses are spooled onto the hose reel prior to shipping.

Power (Closed-Loop) Hydraulic Hoses 225 ft. (68.58 m) x 2 in., 5000 psi (34.5 MPa) hoses; these supply closed-loop hydraulic

oil from the pump drive module to the top drive motors for 1205 hp units: two supply hoses and two return hoses for 750 hp units: one supply hose and one return hose

Auxiliary Hydraulics one 225 ft. (68.58 m) x 3/4 in. R2, 2,000 psi (13.8 MPa) hydraulic hose; this supplies

hydraulic oil from the pump drive module to the top drive robotics system

Case Drain one 225 ft. (68.58 m) x 1-1/4 in. 1,625 psi (11.2 MPa) hydraulic hose; this returns auxil-

iary hydraulic oil and motor case drain flow from the top drive to the hydraulic oil reser-voir

Control Cables

The 225 ft. control cable is spooled onto its own cable reel. The 160 ft. control cable remains attached to the main electrical panel on the power unit and hangs from a cable hook during storage.

one 225 ft. (68.58 m) 37-conductor cable: this cable connects the driller's panel to the top drive

one 160 ft. (48.77 m) 37-conductor cable: this cable connects the driller's panel to the main electrical panel on the power unit

Drillers Panel

The drillers panel is a stainless steel enclosure that is mounted on the drill floor during instal-lation procedures. It contains all controls, indicators, mounts, gauges and connectors required to operate the top drive. There is an optional air-purge system available for the drillers panel. All controls are electrically activated hydraulic (24 VDC) non-earth ground.



OPTIONS

The following options are available. For more detailed information, contact a Tesco represen-tative.

Integrated Rotary Swivel

Rotary swivels with an integrated one-piece quill are available for the HCI(S) Top Drive Sys-tem. Integrated swivel and quill configurations offer the following advantages:

no connections from the swivel bearing to the top of the mudsaver valve increased reliability, which results in reduced maintenance decrease in overall length and weight of the top drive

Elevators and Elevator Links

Elevators rated at 250 and 350 tons (226.8 and 317.5 metric tons), associated inserts for vari-ous drill pipe sizes, and accessories are available. A variety of link lengths is also available.

Additional Safety Valve and Actuator

Several sizes and thread types are available.

Subs

A complete selection of commonly used saver, casing, cross-over and drill collar handling subs is available. Non-standard subs can be manufactured if requested; delivery can be deter-mined at time of order.

Grabber Drill Pipe Guides

These are used to guide the drill string into the grabber box. The drill pipe guide must match the box of the drill pipe in use. There is a range of sizes available.

Rotary Table Stabilizer Bushings

These urethane bushings fit the standard rotary table profile and protect the table and Blowout Preventer (BOP) from excessive wear. There is a range of sizes available.

Rotary Hose and Standpipe Extension

All equipment and accessories for these modifications are available.

Torque Arrest System

Optional equipment for non-standard and large mast torque arrest systems is available.



Other Available Options stacking kit for power system components air purge system for the driller's panel and top drive junction box workshop/parts containers with workbench and storage cupboards camera system water-based oil coolers

Title PageCopyright and DisclaimerRevision InformationTable of ContentsChapter 1: About This DocumentChapter 2: Top Drive System DescriptionIntroduction and General SpecificationsShipping ContainersTop Drive ComponentsPower UnitTorque Arrest SystemService LoopOptions

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880001 d